Exothermic reaction welding molds, weld-metal containing cartridges for such molds, and methods of use

ABSTRACT

Exothermic welding molds, weld-metal containing cartridges for such molds, and methods of use are provided. The mold, cartridges, and methods can provide interaction between the cartridge&#39;s disk member with the mold, which allows the housing member to be withdrawn from the mold while leaving the disk member and weld-metal in place. The interaction can be a rotational restraint alone, a vertical restraint alone, or combinations thereof. Alternately, the interaction can be an outward pressure on the housing member and/or disk member, a shear force on the housing member and/or disk member, or combinations thereof. The outward pressure on the housing member and/or disk member can alternately be provided without interaction between the disk member and the mold, but rather by the simple application of an internal pressure to the cartridge. The internal pressure can be applied by squeezing the walls of the cartridge and/or by depressing a pusher member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 16/269,025filed Feb. 6, 2019, now pending, which is a divisional of U.S.application Ser. No. 15/137,247 filed on Apr. 25, 2016 and issued asU.S. Pat. No. 10,239,162 on Mar. 26, 2019, which claims the benefit ofU.S. Provisional Application 62/152,651 filed on Apr. 24, 2015, theentire contents of all of which are incorporated herein by reference.

BACKGROUND 1. Field of the Disclosure

The present disclosure is related to exothermic welding. Moreparticularly, the present disclosure is related to exothermic weldingmolds, weld-metal containing cartridges for such molds, and methods ofuse.

2. Description of Related Art

The use of exothermic reaction welding is known for joining variousconnectors and/or conductors to each other such as, but not limited to,stranded wire conductors, ground rods, connector lugs, and others.

During such welding, it is common to employ a reusable mold that has areaction chamber in fluid communication with a weld cavity, which ispositioned below the reaction chamber. In this process, portions of thecomponents to be welded together are placed in the weld cavity—eitherbefore or after insertion of the weld materials. During insertion of theweld materials, a metal disk or plug is often placed at the bottom ofthe reaction chamber, to temporarily seal off the passageway betweenweld chamber from the reaction chamber, and an exothermic weld-metal isplaced in the reaction chamber.

The weld-metal is ignited such that an exothermic reaction results inthe reaction chamber. The weld-metal liquefies and melts the disk orplug to allow the molten material to flow into the weld cavity, whichwelds together the components within the cavity.

The process of installing the metal disk or plug and filling thereaction chamber with weld-metal occurs in the field and—often times—indifficult conditions, which can increase the time necessary to form thedesired welds, can result in improper welds, and other disadvantageousresults.

Thus, it has been determined by the present disclosure that there is aneed for molds, weld-metal containing cartridges, and methods of usethat overcome, alleviate, and/or mitigate one or more of theaforementioned and other deleterious effects of the prior art.

SUMMARY

Exothermic welding molds, weld-metal containing cartridges for suchmolds, and methods of use are provided. The mold, cartridges, andmethods can provide interaction between the cartridge's disk member withthe mold, which allows the housing member to be withdrawn from the moldwhile leaving the disk member and weld-metal in place.

In some embodiments, the interaction between the mold and the diskmember is a rotational restraint alone, a vertical restraint alone, orcombinations of rotational and vertical restraints.

In other embodiments, the interaction between the mold and the diskmember is an outward pressure on the housing member and/or disk member,a shear force on the housing member and/or disk member, or combinationsthereof.

In still other embodiments, the outward pressure on the housing memberand/or disk member is provided without interaction between the diskmember and the mold, but rather by the simple application of an internalpressure to the cartridge. The internal pressure can be applied bysqueezing the walls of the cartridge and/or by depressing a pushermember.

The method includes dropping a weld-metal containing cartridge into amold so that a protrusion of a disk member is received in an indentationof the mold; rotating the mold and cartridge with respect to one anotherso that the disk member is released from a housing member of thecartridge; and withdrawing the housing member from the mold so that diskmember and the weld-metal within the cartridge remain in the mold.

An exothermic reaction welding mold is provided that includes a reactionchamber having a shoulder and a wall positioned above a passageway. Thewall has at least one radially extending indentation defined therein. Insome embodiments, the radially extending indentation further includes anundercut area.

An exothermic weld-metal containing cartridge is also provided thatincludes a housing member and a disk member. The housing member has ahorizontal slot depending from a vertical slot. The disk member has aradially extending protrusion depending therefrom. The disk member issecured to the housing member with the radially extending protrusion inthe horizontal slot. The disk member is removable from the housingmember by rotation of the disk and housing members with respect to oneanother so that the extending protrusion is aligned with the verticalslot.

In some embodiments, the cartridge further includes exothermicweld-metal in the housing member. Additionally, the exothermicweld-metal can include an ignition material that is remote from the diskmember.

In other embodiments, the housing member can include an upper retainingrim opposite the disk member and a pusher member slidably received inthe housing member. The upper retaining rim prevents withdrawal of thepusher member from the housing member.

The housing member can also include a lower support rim to abut againstand support the disk member.

A method of using exothermic reaction welding molds and cartridges isprovided. The method includes dropping a weld-metal containing cartridgeinto a mold so that a protrusion of a disk member is received in anindentation of the mold; rotating the mold and cartridge with respect toone another so that the disk member is released from a housing member ofthe cartridge; and withdrawing the housing member from the mold so thatdisk member and the weld-metal within the cartridge remain in the mold.

In some embodiments, the rotating step includes rotating the mold andcartridge with respect to one another so that the protrusion is receivedin an undercut area of the mold and rotating the mold and housing memberwith respect to one another so that the disk member is released from thehousing member.

In other embodiments, the withdrawing step includes pushing on a pushermember so that the pusher member slides in the housing member whilewithdrawing the housing member from the mold so that disk member and theweld-metal within the cartridge remain in the mold.

The above-described and other features and advantages of the presentdisclosure will be appreciated and understood by those skilled in theart from the following detailed description, drawings, and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is top view of an exemplary embodiment of an exothermic reactionwelding mold according to the present disclosure;

FIG. 2A is top perspective view of the mold of FIG. 1 taken along lines2-2;

FIG. 2B is side view of the mold of FIG. 1 taken along lines 2-2;

FIG. 3 is a bottom perspective view of an exemplary embodiment of aweld-metal containing cartridge for use with the mold of FIG. 1 ;

FIG. 4 is a side perspective view of the cartridge of FIG. 3 ;

FIG. 5 is a bottom perspective view of a housing member of the cartridgeof FIG. 3 ;

FIG. 6 is a top view of a removable disk member of the cartridge of FIG.3 ;

FIGS. 7A-7D illustrate an exemplary embodiment of a method of using themold of FIG. 1 with the cartridge of FIG. 3 ;

FIG. 8 is top view of an alternate exemplary embodiment of an exothermicreaction welding mold according to the present disclosure;

FIG. 9A is top perspective view of the mold of FIG. 8 taken along lines9-9;

FIG. 9B is side view of the mold of FIG. 8 taken along lines 9-9;

FIG. 10 is a perspective view of an alternate exemplary embodiment of aweld-metal containing cartridge for use with the mold of FIG. 8 ;

FIG. 11 is a disassembled perspective view of the cartridge of FIG. 10 ;

FIGS. 12A-12D illustrate an exemplary embodiment of a method of usingthe mold of FIG. 8 with the cartridge of FIG. 10 ;

FIG. 13 is a bottom perspective view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 14 is a sectional view of the cartridge of FIG. 13 ;

FIG. 15 is a partially disassembled view of the cartridge of FIG. 13 ;

FIG. 16 is a sectional view of the cartridge of FIG. 13 in use withanother exemplary embodiment of an exothermic reaction welding moldaccording to the present disclosure;

FIG. 17 is a sectional view of the mold of FIG. 16 after removal of thecartridge;

FIG. 18 is a top view of the mold of FIG. 16 ;

FIG. 19 is a top perspective sectional view of an alternate exemplaryembodiment of the cartridge of FIG. 13 ;

FIG. 20 is a partially disassembled view of the cartridge of FIG. 19 ;

FIG. 21 is a bottom perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 22 is a top perspective sectional view of the cartridge of FIG. 21in use with another exemplary embodiment of an exothermic reactionwelding mold according to the present disclosure;

FIG. 23 is a magnified sectional view of the cartridge and mold of FIG.22 ;

FIG. 24 is a partially disassembled view of the cartridge of FIG. 21 ;

FIG. 25 is a bottom perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 26 is a partially disassembled view of the cartridge of FIG. 25 ;

FIG. 27 is a sectional view of the cartridge of FIG. 25 in use withanother exemplary embodiment of an exothermic reaction welding moldaccording to the present disclosure;

FIG. 28 is a bottom perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 29 is a partially disassembled view of the cartridge of FIG. 28 ;

FIG. 30 is a top perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure in use with another exemplary embodiment of an exothermicreaction welding mold according to the present disclosure;

FIG. 31 is a bottom perspective sectional view of the cartridge of FIG.30 ;

FIG. 32 is a side perspective sectional view of an alternate exemplaryembodiment of a housing member according to the present disclosure;

FIG. 33 is a sectional view of the housing member and removable diskmember of FIG. 32 in use with a mold;

FIG. 34 is a bottom perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 35 is a bottom perspective sectional view of an alternate exemplaryembodiment of the cartridge of FIG. 34 ;

FIG. 36 is a bottom perspective sectional view of an alternate exemplaryembodiment of a weld-metal containing cartridge according to the presentdisclosure;

FIG. 37 is a partially disassembled view of the cartridge of FIG. 36 .

DESCRIPTION

Generally, the exothermic welding molds, weld-metal containingcartridges for such molds, and methods of use are provided. The mold,cartridges, and methods can provide interaction between the cartridge'sdisk member with the mold, which allows the housing member to bewithdrawn from the mold while leaving the disk member and weld-metal inplace.

In the embodiments of FIGS. 1-7D, 13-18, and 19-20 , respectively, theinteraction between the mold and the disk member is a combination ofboth a rotational restraint and a vertical restraint alone.

In the embodiments of FIGS. 8-12D, 25-27, and 28-29 , respectively, theinteraction between the mold and the disk member is a rotationalrestraint only.

In the embodiment of FIGS. 21-24 , the interaction between the mold andthe disk member is a vertical restraint only.

In the embodiment of FIGS. 30-31 , the interaction between the mold andthe disk member provides an outward pressure on the housing memberand/or disk member, a shear force on the housing member and/or diskmember, or combinations thereof.

Contrary to the embodiments of FIGS. 1-31 that provide interactionbetween the mold and the disk member, the embodiments of FIGS. 32-37require no such interaction.

Rather in the embodiments of FIGS. 32-37 , the weld-metal containingcartridges are configured so that outward pressure on the housing memberand/or disk member is applied by a simple application of an internalpressure to the cartridge. The internal pressure can be applied bysqueezing the walls of the cartridge as in the embodiments FIGS. 32-33,34, and 35 , respectively, and/or by depressing a pusher member as inthe embodiment of FIGS. 36-37 .

DETAILED DESCRIPTION

Referring to the drawings and in particular to FIGS. 1, 2A, and 2B, anexemplary embodiment of an exothermic reaction welding mold according isshown and is generally referred to by reference numeral 10.Additionally, an exemplary embodiment of a weld-metal containingcartridge for use with the mold of FIG. 1 is shown and is generallyreferred to by reference numeral 12 is shown in FIGS. 3-6 .

Mold 10 and cartridge 12 are described in detail below with simultaneousreference to FIGS. 1-6 . Generally, mold 10 includes one or moreradially extending indentations 14 and one or more undercut areas 16(two shown of each). Cartridge 12 includes a housing member 18 and aremovable disk member 20, which includes one or more radially extendingprotrusions 22 depending therefrom.

Cartridge 12 can be filled with exothermic weld-metal 24 of anycomposition sufficient to weld desired components to one another. Insome embodiments, weld-metal 24 is in powdered form. Of course, it iscontemplated by the present disclosure for weld-metal 24 to have anydesired form such as, but not limited to, a single solid form, multiplesolid portions, and combinations of solid and powdered portions.

Advantageously, indentations 14 are configured to receive protrusions 22of cartridge 12 when the cartridge is placed into mold 10. Then, uponrotation of mold 10 and cartridge 12 with respect to one another,undercut areas 16 are configured to receive and engage protrusions 22.

Cartridge 12 includes horizontal slots 26 and vertical slots 28. Diskmember 20 is received in an inner dimension of housing member 18 withprotrusions 22 received in horizontal slots 26. In this position, diskmember 20 is removably secured to housing member 18 by protrusions 22with the protrusions acting in a manner similar to bayonet-typeconnections.

Once protrusions 22 are engaged in areas 16, further rotation ofcartridge 12 releases housing member 18 from disk member 20 by rotatingthe disk member with respect to the housing member until the protrusionsare free of horizontal slots 26 and are aligned with vertical slots 28.After protrusions 22 are aligned with vertical slots 28, housing member18 can be withdrawn from mold 10 with disk member 20 being retained inposition in the mold 10.

It should be recognized that cartridge 12 is described above by way ofexample as having disk member 20 in an inner dimension of housing member18 so that protrusions 22 serve two functions, namely removably securingthe disk member to the housing member and extending outward from thecartridge for receipt in and engagement with indentations 14 andundercut areas 16, respectively. Of course, it is contemplated by thepresent disclosure for disk member 20 to be secured to an outerdimension of housing member 18 via a first connection (not shown) suchas a threaded or other rotation releasable connection in a manner thatallows protrusions 22 to serve only a single functions, namely removablysecuring the disk member to the housing member and extending outwardfrom the cartridge for receipt in and engagement with indentations 14and undercut areas 16, respectively.

As housing member 18 is withdrawn from mold 10, weld-metal 24 isreleased from the housing member and remains on disk member 20 in thedesired position within mold 10. Thus, mold 10 and cartridge 12 areconfigured so that protrusions 22 of disk member 20 are retained bothrotationally and vertically in the mold, allowing easy withdrawal ofhousing member 18.

Simply stated, mold 10 and cartridge 12 provide a system to install andsecure disk 20 in the desired position in the mold and fill the moldwith weld-metal 24 in a simple and repeatable manner. Additionally,cartridge 12 can prevent or at least mitigate exposure of weld-metal 24to moisture before use.

Returning again to FIGS. 1, 2A, and 2B, mold 10 includes a first portion30 and a second portion 32 that, when positioned adjacent one anotherdefine a reaction chamber 34 having an open top 36 and a passageway 38that leads to a weld chamber (not shown). First and second portions 30,32 are then held in the desired position in any desired method such asusing clamps known in the art.

It should be recognized that first and second portions 30, 32 areillustrated for ease of description as being symmetrical mirror imagesof one another. Of course, it is contemplated by the present disclosurefor portions 30, 32 to have any desired configuration. Thus in theillustrated embodiment, the part line between first and second portions30, 32 is positioned so that a portion of indentations 14 are present ineach portion, while one undercut area 16 is in present in only oneportion and the other undercut area 16 is in present in only the otherportion.

Reaction chamber 34 has a shoulder 40 that receives disk member 20 and awall 42 depending from the shoulder. In the illustrated embodiment,indentation 14 and undercut area 16 are positioned in wall 42 so thatprotrusions 22 are received in the indentations and can be received inthe undercut areas when disk member 20 is received on shoulder 40.

Thus, mold 10 and cartridge 12 are illustrated having disk 20 andshoulder 40 with corresponding shapes. In the illustrated embodiment,disk 20 has a tapered bottom surface with an angle of about 120 degrees,while shoulder 40 has a tapered upper surface with an angle of about 120degrees. Of course, it is contemplated by the present disclosure fordisk 20 and shoulder 40 to have any desired corresponding ornon-corresponding shape.

Mold 10 and more specifically first and second portions 30, 32 are, insome embodiments formed from graphite. Cartridge 12, in someembodiments, includes housing member 18 formed of materials such as, butnot limited to, polymers including thermoplastic and thermoset polymers,fibers materials, paper or paper composites, ceramic, porcelain,graphite, metals including aluminum or aluminum alloys, and any othermaterial having the desired oxygen and/or moisture protectionproperties, while disk member 20 is formed from metal such, as but notlimited to, steel, copper, aluminum, and others.

In some embodiments, cartridge 12 can include one or more identifyingindicia that allow the user to visually identify one or more attributesof the cartridge such as, but not limited to, catalog number, productnumber, the cartridge size, mold type, weld-material type, serialnumber, barcode, and others. The identifying indicia can include a colorof housing member 18 and/or disk member 20, a label on the and/or diskmember, and other indicia.

Disk member 20 is sufficient to temporarily seal off passageway 38between reaction chamber 34 and the weld chamber to allow weld-metal 24,once ignited in the reaction chamber, to reach a desired temperatureand/or reaction state before melting through the disk member andpassing, under the effect of gravity, through the passageway into theweld chamber.

In some embodiments, weld-metal 24 includes an ignition material 44.During assembly of cartridge 12, ignition material 44 is, preferablyplaced into housing member 18 before weld-metal 24 so that the ignitionmaterial is remote or opposite disk member 20. In this manner, ignitionmaterial 44—after removal of housing member 18—is accessible to the userthrough open top 36 of mold 10.

It should be recognized that cartridge 12 and mold 10 can have anydesired number of protrusions 22 and indentations 14/undercut areas 16sufficient to retain (rotationally and vertically) disk member 20 in themold. Moreover, it should be recognized that cartridge 12 and mold 10are described by way of example as having protrusions 22 on disk member20 and indentations 14 on the mold. Of course, it is contemplated by thepresent disclosure for mold 14 to have protrusions and disk member 20 tohave indentions sufficient to retain (rotationally and vertically) diskmember 20 in the mold.

Referring now to FIGS. 7A-7D, a method of using mold 10 and cartridge 12is described and is generally referred to by reference numeral 50.

Method 50 includes a first or drop-in step 52 where cartridge 12 isinserted vertically through open top 36 of mold 10. During drop-in step52, cartridge 12 is placed in mold 10 so that protrusions 22 arereceived in indentations 14, the bottom surface of disk member 20 issupported by shoulder 40 of the mold, and the disk member coverspassageway 38 at the bottom of reaction chamber 34.

Method 50 further includes a second or protrusion-locking step 54 whereprotrusions 22 are locked to mold 10. During protrusion-locking step 54,cartridge 12 is rotated with respect to mold 10 until protrusions 22 arereceived in undercut areas 16 of the mold.

It should be recognized that protrusion-locking step 54 is described byway of example only as rotating cartridge 12 with respect to mold 10. Ofcourse, it is contemplated by the present disclosure for step 54 toinclude any rotation of mold 10 and cartridge 12 with respect to oneanother.

The rotation of cartridge 12 with respect to mold 10 is continued instep 54 until contact and/or the friction between protrusions 22 andundercut areas 16 is greater than the friction between the protrusionsand horizontal slots 26 in housing member 18. At this point, method 50includes a third or disk-removal step 56.

During disk-removal step 56, cartridge 12 is rotated—with protrusions 22held in place by undercut areas 16, so that the protrusions slide withinhorizontal slots 26 until the protrusions are aligned with verticalslots 28.

Simply stated, protrusion-locking step 54 and disk-unlocking step 56serve to secure disk member 20 in mold 10 and to unlock or free the diskmember from housing member 18.

Method 50 further includes a fourth or housing-removal step 58. Duringhousing-removal step 58, housing member 18 is lifted from mold 10 suchthat protrusions 22 slide vertically through slots 28 of the housingmember—leaving disk member 20 in place in the mold and allowingweld-metal 24 to release and/or flow from the housing member intoreaction cavity 34.

In embodiments where cartridge 12 weld-metal 24 includes ignitionmaterial 44, the ignition material—after removal of housing member 18during step 58—is accessible to the user through open top 36 of mold 10.

Alternate exemplary embodiments of an exothermic reaction welding mold110, a weld-metal containing cartridge 112, and method 150 according tothe present disclosure are described with simultaneous reference toFIGS. 8, 9A-9B, 10-11, and 12A-12D. Here, component parts performingsimilar and/or analogous functions to those discussed above are labeledin multiples of one hundred and various elements that may or may havenot been changed have been omitted for purposes of brevity.

Mold 110 and cartridge 112, much like mold 10 and cartridge 12 discussedabove, include one or more radially extending indentations 114 and ahousing member 118 and a removable disk member 120, which includes oneor more radially extending protrusions 122 depending therefrom. However,mold 110 lacks the undercut areas 16 discussed above with respect tomold 10.

Indentations 114 are configured to receive protrusions 122 of cartridge112 when the cartridge is placed into mold 110. Then, upon rotation ofmold 110 and cartridge 112 with respect to one another, indentations 114engage protrusions 122 to prevent rotation of disk member 120 withrespect to housing member 118.

Cartridge 112 includes horizontal slots 126 and vertical slots 128. Diskmember 120 is received in an inner dimension of housing member 118 withprotrusions 122 received in horizontal slots 126. In this position, diskmember 120 is removably secured to housing member 118 by protrusions 122with the protrusions acting in a manner similar to bayonet-typeconnections.

Once protrusions 122 are received in indentations 114, rotation ofcartridge 112 releases housing member 118 from disk member 120 byrotating the disk member with respect to the housing member until theprotrusions are free of horizontal slots 126 and are aligned withvertical slots 128. After protrusions 122 are aligned with verticalslots 128, housing member 118 can be withdrawn from mold 110.

Thus, mold 110 and cartridge 112 are configured so that protrusions 122of disk member 120 are retained rotationally in the mold, allowing easyrelease of the disk member from the housing member. However since diskmember 120 is not retained with respect to vertical movement in mold110, cartridge 112 further includes a pusher member 118-1 for weld-metal124 within housing member 118.

Pusher member 118-1 is slidably positioned in housing member 118 in aposition opposite disk member 120. Once protrusions 122 of disk member120 has been released from horizontal slot 126 and are aligned withvertical slot 128, downward pressure on pusher member 118-1 can be usedto push weld-metal 124 from the housing member will keeping the diskmember in place in mold 110.

In some embodiments, housing member 118 can include an upper retainingring 118-2 to preview inadvertent withdrawal of pusher member 118-1 fromthe upper edge. Rather, retaining ring 118-2 can ensure that pushermember 118-1 can only be slid within housing member 118 towards diskmember 120 after protrusions 122 of the disk member have been alignedwith vertical slots 128.

In this manner and similar to the embodiment discussed above, as housingmember 118 is withdrawn from mold 110 and pressure is applied to pushermember 118-1, weld-metal 124 is released from the housing member andremains on disk member 120 in the desired position within mold 110.

It should be recognized that cartridge 112 is described above by way ofexample as having disk member 120 in an inner dimension of housingmember 118 so that protrusions 122 serve two functions, namely removablysecuring the disk member to the housing member and extending outwardfrom the cartridge for receipt in indentations 114. Of course, it iscontemplated by the present disclosure for disk member 120 to be securedto an outer dimension of housing member 118 via a first connection (notshown) such as a threaded or other rotation releaseable connection in amanner that allows protrusions 122 to serve only a single function,namely removably securing the disk member to the housing member andextending outward from the cartridge for receipt in indentations 114.

Referring now to FIGS. 12A-12D, a method of using mold 110 and cartridge112 is described and is generally referred to by reference numeral 150.

Method 150 includes a first or drop-in step 152 where cartridge 112 isinserted vertically through open top 136 of mold 110. During drop-instep 152, cartridge 112 is placed in mold 110 so that protrusions 122are received in indentations 114, the bottom surface of disk member 120is supported by shoulder 140 of the mold, and the disk member coverspassageway 138 at the bottom of reaction chamber 134.

In the illustrated embodiment, indentations 114 positioned in wall 142so that protrusions 122 are received in the indentations when diskmember 120 is received on shoulder 140.

Method 150 lacks the second or protrusion-locking step 54 discussedabove. Rather, method 150 merely includes a third or disk-removal step156 in which cartridge 112 is rotated—with protrusions 122 held in placeby indentations 114, so that the protrusions slide within horizontalslots 126 until the protrusions are aligned with vertical slots 128. Inthis manner, disk-unlocking step 156 serves to unlock or free diskmember 120 from housing member 118.

Method 150 further includes a fourth or housing-removal step 158. Duringhousing-removal step 158, housing member 118 is lifted from mold 110while downward pressure is applied to pusher member 118-1 such thatprotrusions 122 slide vertically through slots 128 of the housingmember—leaving disk member 120 in place in the mold and allowingweld-metal 124 to be pushed from and/or flow from the housing memberinto reaction cavity 134.

Alternate exemplary embodiments of a weld-metal containing cartridge 312and an exothermic reaction welding mold 310 according to the presentdisclosure are described with simultaneous reference to FIGS. 13-18 .Component parts performing similar and/or analogous functions to thosediscussed above are labeled in multiples of three hundred and variouselements that may or may have not been changed have been omitted forpurposes of brevity.

Cartridge 312 includes housing member 318 and disk member 320 withweld-metal 324 therein. Housing and disk member are removably connectedto one another by way of protrusions 322, horizontal slots 326, andvertical slots 328 in a manner similar to that disclosed above withrespect to FIGS. 3-6 .

Cartridge 312 further includes a seal 360 that is secured to a rim 362of housing member 318. Seal 360 is, for example, an o-ring or othersealing member that, when housing and disk members 318, 320 areconnected to one another forms a seal between the disk member and rim362. In some embodiments, seal 360 forms a hermetic seal that preventsthe egress of water and moisture into weld-metal 324.

Additionally, cartridge 312 includes a separate area 364 opposite diskmember 320, where the separate area is sufficient to store an ignitionmaterial 344 separate from weld-metal 324. Preferably, separate area 364is sealed before use by a removable cap 366. In this manner, cartridge318 is configured so that after providing weld-metal 324 into mold 310,ignition material 344 can be provided either onto the weld metal (notshown) or, alternately onto mold lid 368 as shown in FIG. 17 .

Mold 310 includes indentations 314 and undercut areas 316 that receiveprotrusions 322 of disk member 320 in a manner similar to that disclosedabove with respect to FIGS. 3-6 . Here, undercut areas 316 have apreferably rotational area 370 as shown in FIG. 18 . Without wishing tobe bound by any particular theory, undercut areas 316 with rotationalarea 370 provides increased clearance with the mold 310, which canassist the user during cleaning of slag and/or unused weldament betweenuses.

Further, the rotational shape of areas 370 have been found by thepresent disclosure to ease in manufacture of mold 310 by allowing theareas to be easily undercut into the mold using a circular cutting blade(not shown).

It should be recognized that cartridge 312 is illustrated with respectto FIGS. 13-18 by way of example in use with mold 310 that includesundercuts 316—namely to remove disk member 320 using both vertical androtational interactions. Of course, it is contemplated by the presentdisclosure for cartridge 312 to find equal use with molds such as thoseillustrated in FIGS. 7A-9A—namely to remove disk member 318 using onlyrotational interaction. Thus, cartridge 312 is illustrated in FIGS.19-20 further including pusher member 318-1 and retaining rim 318-2 in amanner similar to those described with respect to FIGS. 10-11 for usewith this and/or other embodiments.

Other alternate exemplary embodiments of a weld-metal containingcartridge 412 and an exothermic reaction welding mold 410 according tothe present disclosure are described with simultaneous reference toFIGS. 21-24 . Component parts performing similar and/or analogousfunctions to those discussed above are labeled in multiples of fourhundred and various elements that may or may have not been changed havebeen omitted for purposes of brevity.

Advantageously, mold 410 and cartridge 412 are configured to allowremoval of disk member 420 from housing member 418 using only a verticalinteraction between the disk member and mold 410.

Here, disk member 420 has an inner dimension that forms a press fit orinterference fit with an outer dimension of housing member 418. Althoughnot shown, it is further contemplated by the present disclosure for thepress fit or interference fit between housing member 418 and disk member420 to be formed between an inner dimension of the housing member and anouter dimension of the disk member.

Mold 410 includes undercut 416 that receives protrusions 422 of diskmember 420 in a snap fit manner. For example, mold 410 can include alead-in 472 that inwardly resiliently biases protrusions 422 duringinsertion of cartridge 412 into mold 410. Upon protrusions 422 clearinglead in 472, protrusions 422 are received in undercut 416 in a mannerthat prevents or restrains upward vertical movement of disk member 420,which allows the action of withdrawing housing member 418 from mold 410to overcome the press fit or interference fit between housing and diskmembers 418, 420.

Without wishing to be bound by any particular theory, the inwardresilient biasing protrusions 422 can be a function of the materialproperties and structure of one or more disk member 420, housing member422, and combinations thereof.

Other alternate exemplary embodiments of a weld-metal containingcartridge 512 and an exothermic reaction welding mold 510 according tothe present disclosure are described with simultaneous reference toFIGS. 25-29 . Component parts performing similar and/or analogousfunctions to those discussed above are labeled in multiples of fivehundred and various elements that may or may have not been changedhaving been omitted for purposes of brevity.

Advantageously, mold 510 and cartridge 512 are configured to allowremoval of disk member 520 from housing member 518 using only arotational interaction between the disk member and mold 510.

In FIGS. 25-27 , disk member 520 is illustrated having been threadablyreceived on an inner dimension of housing member 518 by cooperatingthreads 574, 576, respectively. Conversely, disk member 520 isillustrated having been threadably received on an outer dimension ofhousing member 518 by cooperating threads 574, 576, respectively.

In order to facilitate the rotational restraint, disk member 520includes one or more non-circular surfaces 522, illustrated as flatregions and mold 510 includes a corresponding number of non-circularmating surfaces 516, also illustrated as flat regions. In this manner,when cartridge 512 is inserted into mold 510 with surfaces 516, 522adjacent one another, rotational movement imparted to housing member 518is not translated to disk member 520, but rather results in cooperatingthreads 574, 576 unthreading from one another.

Although not shown in FIGS. 25-29 , it is contemplated by the presentdisclosure for cartridge 512 to include a seal secured to housing member518, where the seal can form a hermetic seal that prevents the egress ofwater and moisture into weld-metal 524.

Other alternate exemplary embodiments of a weld-metal containingcartridge 612 and an exothermic reaction welding mold 610 according tothe present disclosure are described with simultaneous reference toFIGS. 30-31 . Component parts performing similar and/or analogousfunctions to those discussed above are labeled in multiples of sixhundred and various elements that may or may have not been changedhaving been omitted for purposes of brevity.

In this embodiment, the interaction between mold 610 and cartridge 612impart an outward pressure on housing member 618 and/or disk member 620,a shear force on the housing member and/or disk member, or combinationsthereof.

For example, disk member 620 can—in some embodiments be a pierceablefoil—that has sufficient rigidity to temporarily seal off passageway 638between reaction chamber 634 and the weld chamber to allow weld-metal624, once ignited in the reaction chamber, to reach a desiredtemperature and/or reaction state before melting through the disk memberand passing, under the effect of gravity, through the passageway intothe weld chamber. Here, mold 610 can include elements 616 that interactwith disk member 620 during insertion of cartridge 612 into the mold soas to pierce through the disk member the disk member—and thus separatethe disk member from housing member 618.

In other embodiments, disk member 620 can be removably secured tohousing member 618. Here, elements 616 interact with housing member 618and/or disk member 620 during insertion of cartridge 612 into the moldso as to separate the disk member from housing member 618. For example,elements 616 can apply an outward force on housing member 618 sufficientto deflect the housing member outwards so as to separate disk member 620from the housing member.

Advantageously, the exothermic welding molds, weld-metal containingcartridges for such molds, and methods of use of the present disclosureprovide—in some embodiments—an interaction between the mold and thecartridge in a manner that allows for the removal of the disk memberfrom the housing member once the housing member is within the mold. Insome embodiments, the cartridges and molds of the present applicationuse the same structure that removably secures the disk and housingmembers to one another to also allow removal of the disk member from thehousing member and to ensure a positive fit or location of the diskmember in the mold. In this manner, the molds, cartridges, and methodsof the present application allow for an integrated mold-cartridge systemin a simple, reliable, and repeatable manner.

Of course, it is contemplated by the present disclosure for theexothermic welding molds, weld-metal containing cartridges for suchmolds, and methods of use of the present disclosure to require no suchinteraction between the mold and the cartridge to assist in the removalof the disk member from the housing member.

Examples of non-interacting molds and cartridges are described in moredetail below in which the disk member is removed from the housing memberthrough an outward pressure on the housing member and/or disk memberwithout interaction between the disk member and the mold, but rather bythe simple application of an internal pressure to the cartridge. Theinternal pressure can be applied by squeezing the walls of the cartridgeand/or by depressing a pusher member as discussed in more detail below.

Referring now to FIGS. 32-33 , alternate exemplary embodiments of thehousing member according to the present disclosure is shown and isgenerally referred to by reference numeral 218. Here, component partsperforming similar and/or analogous functions to those discussed aboveare labeled in multiples of two hundred and various elements that may ormay have not been changed have been omitted for purposes of brevity.

Housing member 218 can include a lower support rim 218-3 to abut againstand support disk member 220 to ensure proper positioning of the diskmember with respect to the housing member and to guide the flow ofweld-metal (not shown) into the disk member.

After insertion of cartridge 212 into mold 210, outward pressure onhousing member 218 and/or disk member 220 is provided withoutinteraction between the disk member and the mold, but rather by thesimple application of an internal pressure to the cartridge. In thisembodiment, the internal pressure can be applied by squeezing the wallsof housing member 218 radially inward as shown in FIG. 33 .

It should be recognized that cartridge 212 is illustrated in FIGS. 32-33as having disk member 220 secured by a press or interference fit into aninternal dimension of housing member 218. Of course, it is contemplatedby the present disclosure for cartridge 212, as illustrated in FIG. 34 ,to have disk member 220 secured by the press or interference fit to anexternal dimension of housing member 218 or for the disk member to havethe structure as shown in FIG. 35 —namely one that does not extendradially outward beyond housing member 218.

In each embodiment, the internal pressure applied to cartridge 212 bysqueezing the walls of housing member 218 is sufficient to overcome theinterference fit between disk member 220 and the housing member so as todisconnect the disk member from the housing member. In some embodiments,it is contemplated by the present disclosure that the squeezing thewalls of housing member 218 also acts to deflect the housing member asufficient distance to disconnect disk member 220 from the housingmember.

It should be recognized that cartridge 212 is illustrated with respectto FIGS. 32-35 as requiring the user to apply the internal pressure bysqueezing the walls of housing member 218. Of course, it is contemplatedby the present disclosure for cartridge 212, as illustrated in FIGS.36-37 , to further including pusher member 218-1 and retaining rim 218-2in a manner similar to those described with respect to FIGS. 10-11 foruse with this and/or other embodiments.

It should also be noted that the terms “first”, “second”, “third”,“upper”, “lower”, and the like may be used herein to modify variouselements. These modifiers do not imply a spatial, sequential, orhierarchical order to the modified elements unless specifically stated.

While the present disclosure has been described with reference to one ormore exemplary embodiments, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of thepresent disclosure. In addition, many modifications may be made to adapta particular situation or material to the teachings of the disclosurewithout departing from the scope thereof. Therefore, it is intended thatthe present disclosure not be limited to the particular embodiment(s)disclosed as the best mode contemplated, but that the disclosure willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. An exothermic reaction welding mold for use witha weld metal containing cartridge that has a removable disc member, themold comprising: a reaction chamber; a weld chamber; and a passagewayproviding communication between the reaction chamber and the weldchamber, wherein the reaction chamber comprises a shoulder positionedabove the passageway on which the removable disc member can be receivedto temporarily seal off the passageway, wherein the reaction chambercomprises a structure that is sized and positioned to interact with theremovable disc member and/or the cartridge to remove the removable discmember from the cartridge.
 2. The mold of claim 1, wherein the structureis sized and configured to interact with the removable disc member asboth a rotational restraint and a vertical restraint so as to remove theremovable disc member from the cartridge during removal of the cartridgefrom the mold.
 3. The mold of claim 2, wherein the wall has at least oneradially extending indentation defined so as to not extend through thewall to an exterior of the reaction chamber.
 4. The mold of claim 3,wherein the at least one radially extending indentation furthercomprises an undercut area defined so as to not extend through the wallto the exterior of the reaction chamber.
 5. The mold of claim 2, whereinthe wall has at least one radially extending indentation defined so asto extend only partially through the wall of the reaction chamber. 6.The mold of claim 5, wherein the at least one radially extendingindentation further comprises an undercut area defined so as to extendonly partially through the wall of the reaction chamber.
 7. The mold ofclaim 1, wherein the structure is sized and configured to interact withthe removable disc member as only a rotational restraint so as to removethe removable disc member from the cartridge during removal of thecartridge from the mold.
 8. The mold of claim 7, wherein the wall has atleast one radially extending indentation defined so as to not extendthrough the wall to an exterior of the reaction chamber.
 9. The mold ofclaim 7, wherein the wall has at least one radially extendingindentation defined so as to extend only partially through the wall ofthe reaction chamber.
 10. The mold of claim 1, wherein the structure issized and configured to interact with the removable disc member as onlya vertical restraint so as to remove the removable disc member from thecartridge during removal of the cartridge from the mold.
 11. The mold ofclaim 10, wherein the wall has an undercut area defined so as to notextend through the wall to the exterior of the reaction chamber.
 12. Themold of claim 10, wherein the wall has an undercut area defined so as toextend only partially through the wall of the reaction chamber.
 13. Themold of claim 1, wherein the structure is sized and configured tointeract with the cartridge by applying an outward pressure on thecartridge to remove the removable disc member from the cartridge duringinsertion of the cartridge into the mold.
 14. The mold of claim 13,wherein the structure is sized and configured to interact with thecartridge by applying a shear force on the cartridge and/or disk memberto remove the removable disc member from the cartridge during insertionof the cartridge into the mold.
 15. The mold of claim 1, wherein thestructure is sized and configured to interact with the cartridge byapplying a shear force on the cartridge and/or disk member to remove theremovable disc member from the cartridge during insertion of thecartridge into the mold.
 16. An exothermic reaction welding mold for usewith a weld metal containing cartridge that has a removable disc member,the mold comprising: a reaction chamber; a weld chamber; and apassageway providing communication between the reaction chamber and theweld chamber, wherein the reaction chamber comprises a shoulderpositioned above the passageway on which the removable disc member canbe received to temporarily seal off the passageway, and wherein thereaction chamber comprises a wall positioned above the passageway, thewall having at least one radially extending indentation defined so as tonot extend through the wall to an exterior of the reaction chamber. 17.The mold of claim 16, wherein the at least one radially extendingindentation further comprises an undercut area defined so as to notextend through the wall to the exterior of the reaction chamber.
 18. Anexothermic reaction welding mold for use with a weld metal containingcartridge that has a removable disc member, the mold comprising: areaction chamber; a weld chamber; and a passageway providingcommunication between the reaction chamber and the weld chamber, whereinthe reaction chamber comprises a shoulder positioned above thepassageway on which the removable disc member can be received totemporarily seal off the passageway, and wherein the reaction chambercomprises a wall positioned above the passageway, the wall having atleast one radially extending indentation defined so as to extend onlypartially through the wall of the reaction chamber.
 19. The mold ofclaim 18, wherein the at least one radially extending indentationfurther comprises an undercut area defined so as to extend onlypartially through the wall of the reaction chamber.